Milling cutter

ABSTRACT

Milling cutter ( 1 ), which can rotate about a cutter longitudinal axis (A), comprises a sleeve-shaped shaft ( 2 ) provided with an inner lying chip evacuation channel ( 11 ), which is arranged, in essence, symmetric to the cutter longitudinal axis (A), and with a suction opening ( 12 ). The milling cutter also comprises a milling head ( 3, 3   a,    3   b,    3   c ), which is held coaxial to the cutter longitudinal axis (A) and to the shaft ( 2 ) while being held on said shaft and which comprises, as cutting edges ( 7, 9 ), a face cutting edge ( 7 ) and a peripheral cutting edge ( 9 ). At least one cutting edge ( 7, 9 ) forms a positive rake angle (γ a , γ r ) on the periphery of the milling head ( 3, 3   a,    3   b,    3   c ). The milling cutter ( 1 ) is particularly suited for machining light metals, especially for circular milling. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, possibly following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.

CONTINUING APPLICATION DATA

This application is a continuation of U.S. patent application Ser. No.10/990,281, filed Nov. 16, 2004, which is a Continuation-In-Partapplication of International Patent Application No. PCT/EP03/05191,filed on May 16, 2003, which claims priority from Federal Republic ofGermany Patent Application No. 102 22 040.9, filed on May 17, 2002.International Patent Application No. PCT/EP03/05191 was pending as ofthe filing date of U.S. patent application Ser. No. 10/990,281. TheUnited States was an elected state in International Patent ApplicationNo. PCT/EP03/05191.

BACKGROUND

1. Technical Field

The present application relates to a milling cutter, in particular formachining light alloy metals, with a shaft and a milling head. Themilling cutter can also have a sleeve-shaped shaft with an internal chipevacuation channel that is located essentially symmetrical to thelongitudinal axis of the milling cutter and a suction aperture. Themilling head is held so that it is coaxial to the longitudinal axis ofthe tool and to the shaft, with a face cutting edge and a peripheralcutting edge as cutting edges.

2. Background Information

Workpieces made of light alloy metals, such as magnesium alloys, forexample, are frequently machined using metal removing processes. In thiscase, however, the formation of mixtures of magnesium dust and air is aproblem. This problem occurs in particular during the dry cutting oflight alloy metals. To address this problem, DE 44 39 114 A1, forexample, discloses a very complex method and a device for dry,metal-removing machining, i.e. machining without a coolant feed, of aworkpiece that is made of light alloy metal, whereby the cutting tool islocated in a closed machining chamber in which a pressure gradient isset so that during the cutting process the machining chips are removedfrom the machining chamber. This chip removal device takes up a verylarge amount of space. The high cost and level of complexity of theapparatus results from the risk of explosion which is particularly greatbecause of the formation of dry magnesium chips and dusts.

However, a risk of explosion during the metal-removing machining oflight alloy metal cannot be prevented even by the use of coolants andlubricants. Aqueous emulsions cannot be used as cooling lubricantsbecause magnesium would react chemically with the water during themachining operations. Therefore the cooling lubricants used must beoil-based. These cooling lubricants, however, have the disadvantage thatthe oil mist which is formed can be explosive, alone or in combinationwith light-alloy metal dust. An additional problem is the health hazardpresented by the aerosols that are formed during machining. The coolinglubricant is also difficult and expensive to reprocess or dispose ofafter it has been used. Another problem, for example, is presented bythe light alloy dust that is deposited on the machine tool or in thevicinity of the machine tool, which creates a risk of explosion not onlyimmediately during the machining process but also when the dust isstirred up at some later time. Thus the specific problems related to thecutting of light alloy metals, in particular magnesium and magnesiumalloys, cannot be eliminated even by the use of cooling lubricants.

OBJECT OR OBJECTS

The object is a device that makes possible a particularly efficientcutting of light alloy metals, in particular magnesium and magnesiumalloys, and which is uncritical from a safety point of view.

SUMMARY

The present application teaches that this object can be accomplished bya milling cutter that has the characteristics according to at least oneembodiment discussed herein. The milling cutter thereby has asleeve-shaped shaft with an internal chip evacuation channel and asuction opening. Coaxial to the longitudinal axis of the tool and to theshaft and held on the shaft is a milling head which has at least oneface cutting edge and at least one peripheral cutting edge. The cuttinggeometry of at least one of the cutting edges, possibly of both theperipheral cutting edge and of the face cutting edge, is positive or hasa positive rake at least on the periphery of the milling head, i.e. theface cutting edge and/or the peripheral cutting edge forms a positiverake angle, possibly a rake angle of at least 10°. The rake angle of theface cutting edge is not necessarily constant over the entire length ofthe face cutting edge. To the extent that the peripheral cutting edge isadjacent to the face cutting edge, the rake angle of the face cuttingedge on the periphery of the milling head also gives the angle of twistof the milling head, which is also called the side angle of rake. Thepositive cutting geometry in all cases guarantees a machining, with verypositive angles of rake in the form of a progressive cut, with lowcutting forces, as a result of which the tool is particularly wellsuited for the cutting of light alloys.

The chips that are formed during the machining of a workpiece areremoved primarily and possibly exclusively through the chip evacuationchannel located in the shaft, in particular symmetrical to thelongitudinal axis of the cutter. The suction opening of the chipevacuation channel is possibly located on the end surface of the shaft,facing the milling head. On account of the removal of the chips bysuction through the tool shaft, no machining chamber is required tosuction away the chips.

The milling cutter is particularly appropriate for the dry cutting oflight alloy metals such as magnesium and magnesium alloys. Because themilling head has at least one face cutting edge and at least oneperipheral cutting edge, the milling cutter is very flexible, and can beused for circular milling, for example. Of course a tool with internalchip removal is known from DE 2 316 762 A, for example, although thetool described in the prior art document is not a milling cutter but aboring tool. This boring tool is intended primarily for the drilling ofdeep borings. The boring tool cannot be used for milling operations.That is particularly apparent from the fact that the boring tool hassupport strips located on the side that guide the boring tool in theboring. By contrast, the milling cutter claimed by the presentapplication has a milling head that makes possible both a feed in theaxial direction, i.e. in the direction of the longitudinal axis of thetool, as well as a feed perpendicular to the longitudinal axis of thetool.

The immediate removal by suction of the chips through the tool shaftprevents chips from being deposited on the processing machine. It alsoprevents thermal deformation of the workpiece and/or of the machine toolcaused by contact with the hot chips. The chips can be at least almostentirely collected and recycled. The ability to do without the externalvacuum removal of the chips that are formed during the machine meansthat the tool can be changed quickly and easily, as can the workpiece inthe machine tool.

The milling head is possibly manufactured in one piece from a cuttingmaterial such as cemented carbide or hard metal. The milling head isthereby particularly stable and can also be used for smaller tooldiameters, such as diameters less than 15 mm, for example. The millinghead has no separate cutting inserts, e.g. of the type that have to besoldered in or screwed on. The fully one-piece configuration of themilling head made of a cutting material also comprises realizations inwhich individual volume or surface areas of the milling head, forexample, in the form of a coating, have a composition or properties thatdiffer from other parts of the milling head.

The diameter of the milling head is possibly greater than the diameterof the shaft, at least in the area of the shaft that is adjacent to themilling head.

It is thereby ensured that during both boring and milling operations, inparticular during circular milling operations, the shaft of the millingcutter does not come into contact with the workpiece to be machined.

The milling head has a one-piece or multiple-piece aperture surface forthe removal of the chips through the chip evacuation channel. Toguarantee a reliable evacuation of the chips and to eliminate the riskof a jammed chip, the aperture surface of the milling head is possiblyat least 35% and in particular at least 50% of the cross section surfaceof the shaft. The configuration of the milling head with correspondinglylow material thicknesses is easy to realize, provided that the millingcutter is designed to be used exclusively for cutting light alloymetals.

The reliable evacuation of chips through the tool shaft is possiblyfacilitated by ensuring that the thickness of the milling head is amaximum of 50% of the diameter of the milling head. The chips arethereby conveyed over a very short distance from the tool into to thechip evacuation channel. The danger of a backup of chips in the millinghead is therefore extraordinarily low.

In one preferred configuration, the milling head has at least threelobes or vanes with at least three face cutting edges and at least threeperipheral cutting edges.

The forces during cutting are thereby distributed at least approximatelysymmetrically, in contrast to a single-lip borer. The configuration ofthe milling head with three or more lobes, in particular with fivelobes, also has the advantage that, for example in comparison to arealization with only two face cutting edges, relatively short chips areformed, which can be easily evacuated through the internal chipevacuation channel. The smaller the chip, the larger its specificsurface. A small chip can therefore be removed particularly efficientlyby an air current in the chip evacuation channel. When a boring is beingmade by circular milling, shorter chips are formed than during boring,regardless of the shape of the milling head. The milling cutter istherefore particularly well suited for circular milling.

In an additional preferred configuration, the milling head is notcompletely rotationally symmetrical. Rather, the end surface or one ofthe end surfaces extends from the periphery of the milling head tobeyond the longitudinal axis of the cutter, whereby the face cuttingedges do not necessarily intersect the longitudinal axis of the cutter.It is thereby impossible for a core, such as a drill core, for example,to get stuck. The workpiece is machined in a defined manner overpractically the entire cross section of the milling cutter, i.e. thereis practically no displacement of material during the machining process.The milling cutter can thereby achieve a long useful life.

The face cutting edge of the milling head is adjacent, possibly on acorner cutting edge, is directly adjacent to the peripheral cuttingedge. The corner cutting edge, which is located in the periphery of themilling head, makes it possible to produce exact contours on theworkpiece. The corner cutting edge is thereby possibly the part of themilling head that is axially farthest from the shaft, with reference tothe direction of the longitudinal axis of the cutter, i.e. the cornercutting edge is the farthest forward inside the milling cutter. If themilling cutter is used to create a depression in a workpiece, bycircular milling, for example, this depression can be completely flat,because the corner cutting edge on the milling head is the farthestforward. One requirement for such an operation is that there must besufficient lateral, i.e. radial freedom of movement during the milling.When the cutter is applied to the workpiece, only the corner cuttingedge initially removes a chip from the workpiece. The cutting forces atthe beginning of the cutting process are therefore very low.

Moreover, a particularly advantageous cutting geometry, in particularfor the cutting of light alloy metals, can be achieved because thecorner cutting edge is realized with an acute angle or sharp point. Toachieve a particularly pronounced sharp-pointed shape of the cornercutting edge, at this point both the face cutting edge and theperipheral or radial cutting edges possibly each form a positive rakeangle, namely an axial rake angle and/or a radial rake anglerespectively. The angle which the peripheral cutting edge on the cornercutting edge bordering the cutting surface of the face cutting edgeencloses with the longitudinal axis of the tool, at this pointdetermines the axial rake angle, i.e. the rake angle of the face cuttingedge. This angle, which forms a twist or spiral angle of the millinghead, is possibly at least 10°, and in particular at least 30°.Simultaneously on the peripheral cutting edge, a radial rake angle onthe corner cutting edge determined by the position of the face cuttingedge is formed, which is possibly also at least 10° and in particular atleast 15°. As a result of the high positive rake of both the axial andthe radial cutting edges, i.e. of the face cutting edge and of theperipheral cutting edge, it is easy to execute both axial and radialfeed movements.

The milling head is connected with the shaft possibly permanently, forexample by soldering. A particularly stable connection can hereby beachieved, in particular when the shaft partly surrounds the millinghead. For this purpose the milling head, for example approximately inthe center of its vertical dimension, has a peripheral step which is incontact toward the shaft with a tapered area of the milling head. Theportion of the milling head that projects beyond the shaft is availablefor the metal removing machining. To make maximum use of this part forthe metal removal, the peripheral cutting edge possibly extends from thecorner cutting edge to the peripheral step.

An increased stability of the shaft can be achieved by making itdouble-walled with an inner shaft and an outer shaft. As a result ofthis double-walled realization, it is possible in particular to utilizethe space between the inner shaft and the outer shaft. The space in theshaft is possibly used for the feed of a fluid, in particular compressedgas, such as compressed air for example, while the inner shaft forms thewall of the chip evacuation channel. The evacuation of the chips can beassisted by the feed of compressed air through a fluid feed apertureprovided for the purpose, which is possibly located on the side of theouter shaft. In addition or alternatively to the compressed air, acooling lubricant can also be fed through the fluid feed aperture. Thefluid channel formed between the inner shaft and the outer shaftpossibly has a helical shape.

This shape has the advantage that the fluid, e.g. cooling lubricant,conducted to the milling head and the machining point on the end of theshaft, has a tangential flow component in addition to the axial flowdirection, and thus immediately removes the chips generated to the chipevacuation channel. The spraying of cooling lubricant at the millinghead can thereby be configured in the manner of a water jet pump. Thehelical fluid channel also makes it possible to locate appropriatelyhelical support elements between the inner shaft and the outer shaft andthus to further increase the stability of the shaft.

The chip evacuation channel should be generously sized in relation tothe diameter of the milling cutter to guarantee the smooth removal ofthe chips. The diameter of the chip evacuation channel is possibly atleast 75% of the shaft diameter. In the case of a double-walled shaft,the inside inner shaft diameter which defines the diameter of the chipevacuation channel is at least 75% of the outside diameter of the outershaft, which is the same as the shaft diameter. The wall thicknesses ofthe outer shaft and of the inner shaft are thereby possibly each amaximum of 10% of the shaft diameter. Because at least the majority ofthe cutting and chucking forces are absorbed by the outer shaft, thewall thickness of the outer shaft possibly exceeds the wall thickness ofthe inner shaft.

The particular advantage is that as a result of an internal chipevacuation channel in a milling cutter, which has a milling head thathas at least one face cutting edge and at least one peripheral cuttingedge, it becomes possible to perform a very efficient machining with anaxial and/or radial feed, in particular the circular milling of aworkpiece, in particular one made of light alloy metal such as magnesiumfor example.

In at least one possible embodiment, the milling cutter may also be usedfor cutting or machining or milling other light metals, such as lightmetal alloys, aluminum, titanium, beryllium alloys, and non-ferrousmetals or metal alloys.

The above-discussed embodiments of the present invention will bedescribed further hereinbelow. When the word “invention” or “embodimentof the invention” is used in this specification, the word “invention” or“embodiment of the invention” includes “inventions” or “embodiments ofthe invention”, that is the plural of “invention” or “embodiment of theinvention”. By stating “invention” or “embodiment of the invention”, theApplicant does not in any way admit that the present application doesnot include more than one patentably and non-obviously distinctinvention, and maintains that this application may include more than onepatentably and non-obviously distinct invention. The Applicant herebyasserts that the disclosure of this application may include more thanone invention, and, in the event that there is more than one invention,that these inventions may be patentable and non-obvious one with respectto the other.

BRIEF DESCRIPTION OF THE DRAWINGS

One exemplary embodiment is explained in greater detail below and isillustrated in the accompanying figures, in which:

FIGS. 1A, 1B, and 1C show in perspective a milling cutter with aninternal chip evacuation channel;

FIGS. 2A to 2C show various views of the milling head of the millingcutter illustrated in FIGS. 1A-1C;

FIGS. 3A to 3E show a shaft of a milling cutter with an internal chipevacuation channel;

FIGS. 4A to 4E show a five-lobed head for a milling cutter with aninternal chip evacuation channel;

FIGS. 5A to 5E show a three-lobed head for a milling cutter with aninternal chip evacuation channel;

FIGS. 6A to 6H an alternative realization of a three-lobed milling head;

FIG. 7 shows a hydraulic expansion chuck with a chucked milling cutter;and

FIGS. 8A to 8D show a milling cutter and a chucking and feed device.

DESCRIPTION OF EMBODIMENT OR EMBODIMENTS

Identical or equivalent parts are identified by the same referencenumbers in all the figures.

FIGS. 1A and 1B show views in perspective, overall and individualsections, of a milling cutter 1 with a shaft 2 and an essentiallydisc-shaped milling head 3. FIGS. 2A to 2C show various views of themilling head 3 by itself. Specifically, FIG. 2A shows the milling head 3from below, i.e. in a view from the shaft 2. FIG. 2B shows the millinghead 3 from above, and FIG. 3C shows a side view of the milling head 3.The shaft 2 of the milling cutter 1 is double-walled with an outer shaft2 a and an inner shaft 2 b. The milling head 3 is shown removed from theshaft 2, to make the details of this realization clearer in FIGS. 1A and1B.

The inner shaft 2 b is located eccentrically in relation to the outershaft 2 a, so that the inner shaft 2 a is in contact, on its periphery,against the outer shaft 4 in a contact area 4 that extends parallel tothe axis A of the milling cutter 1 along the shaft 2. The inner shaft 2b is permanently connected with the outer shaft 2 a at the contact area4, for example by soldering. Opposite the contact area 4 in the shaft 2,between the inner shaft 2 b and the outer shaft 2 a, there is a fluidchannel 5 with an approximately crescent-shaped cross section. A fluidsuch as compressed air and/or cooling lubricant can be fed through thefluid channel 5 to the milling head 3. The milling head 3 has, on itsend surface 6, a face cutting edge 7 and adjacent to the end surface aperipheral cutting edge 9. A chip that is formed at the cutting edges 7,9, in particular a light alloy chip, enters through a space 10 into achip evacuation channel 11 surrounded by the inner shaft 2 b and can beevacuated through a suction opening 12 which is located on the shaft end13 in a thicker region 14 of the shaft 2. The thicker, mechanicallyparticular stable area 14 is used to absorb the chucking forces that areexerted on the milling cutter 1 in the expansion chuck (27) (FIG. 7) orin the housing with vertical evacuation.

The face cutting edge 7 has a radial cutting edge 7 a and adjacent toit, a relatively shorter and partly curved a beveled cutting edge 7 bthat is adjacent to the corner cutting edge 8. Overall, the face cuttingsurface 7 extends from one edge 15 of the milling head 3 essentiallyradially to beyond the tool axis A. At the corner cutting edge 8, theperipheral cutting edge 9 encloses an angle of twist γ which in thisexemplary is constant and is approximately 45°, which corresponds to anaxial angle or rake γ_(a) of the face cutting edge 7 (See FIG. 6G).Simultaneously, the peripheral cutting edge 9, as shown in particular inFIGS. 2A and 2B, has a radial angle of rake γ_(r) of approximately 15 to20°, which is determined on the face end 6 of the milling head 3 by theposition of the face cutting edge 7 and is not necessarily constant overthe entire length of the peripheral cutting edge 9. On the cornercutting edge 8 there is thus a highly positive cutting geometry as aresult of the diagonal position of the cutting edges or cutting segments9, 7 b.

In at least one possible embodiment, the cutting edge 7 b liessubstantially in a plane substantially perpendicular to the longitudinalaxis A of the milling cutter 1. What is meant by the preceding phrase“lies substantially in a plane substantially perpendicular to thelongitudinal axis A” is that the cutting edge 7 b may lie in theperpendicular plane, or may deviate from lying in the perpendicularplane to another position to define an angle with respect to theperpendicular plane, such as around 10°. This angle may be in a range ofsubstantially 0° to an angle somewhat greater than 10°. This angle, forpurposes of disclosure, may vary in typically one degree increments overthis range. Therefore, the cutting edge 7 b lies substantially in aplane substantially perpendicular to the longitudinal axis A, such thatan angle in a range of substantially 0° to an angle somewhat greaterthan 10° is defined by the cutting edge 7 b and the perpendicular plane.

On account of this cutting geometry, the milling cutter 1 isparticularly well suited for cutting light alloy metals, in particularfor high-speed machining operations.

The milling head 3, as shown in particular in FIG. 2C, has a peripheralstep 16, by which a tapered area 17 is delimited from a forward area 18that contains the cutting edges 7, 9. In this tapered area 17, themilling head 3 can be connected with the outer shaft 2 a by soldering,welding or adhesive. The diameter D_(S) of the shaft in its areaadjacent to the milling head 3 is somewhat smaller than the diameterD_(F) of the milling head 3, which is specified as twice the maximumdistance of the peripheral cutting edge 9 from the longitudinal axis ofthe tool.

FIG. 1C is the same view as FIG. 1B, with additional detail,specifically surfaces 101, 102, 103, and 104 of the end surface 6 of themilling head 3. These surfaces 101, 102, 103, 104, in at least onepossible embodiment, could be substantially flat or could have acurvature. In at least one embodiment, surface 101, as seen in FIG. 1C,extends in a downward slope from the cutting edge 7 b to the peripheraledge 105 of the milling head 3 such that the cutting edge 7 b is locatedfurther away from the shank 2 of the milling cutter 1 in the axiallydirection than any point on the surface 101 and the peripheral edge 105of the milling head 3. In one other possible embodiment, cutting edge 7b and the surface 101 or a portion thereof could lie substantially in aplane that is substantially perpendicular to the longitudinal axis A.Surface 102 could be similarly disposed with respect to cutting edge 7 aas surface 101 is to cutting edge 7 b. In at least one embodiment,surfaces 101 and 102, or at least a portion thereof, are located furtheraway from the shank 2 of the milling cutter 1 in the axially directionthan surfaces 103 and 104, or at least a portion thereof. In anotherpossible embodiment, cutting edges 7 a and 7 b are located further awayfrom the shank 2 of the milling cutter 1 in the axially direction thansurfaces 103 and 104. In at least one possible embodiment, the surfaces101, 102, 103, 104 could be individual surfaces disposed at angles withrespect to another, or could be configured as a substantially contiguoussurface with a substantially smooth, constant surface. Additionalvarious configurations of the surfaces of the end face 6 of the millinghead 3 not specifically set forth herein are to be understood as beingwithin the scope of the present application.

FIGS. 3A to 3E show various view of a shaft 2 which is realized in theform of a milling cutter 1, for example with a milling head 3 asillustrated in FIGS. 2A to 2C. The shaft 2 is realized with a doublewall whereby the wall thickness W_(A) of the outer shaft 2 a is greaterthan the wall thickness W_(B) of the inner shaft 2 b (see FIGS. 1A andB). The inner shaft 2 b in this exemplary embodiment (FIGS. 3A-E) islocated symmetrically in the outer shaft 2 a, which in its rear areawhich is provided to hold it in a machine tool and which comprises thethicker area 14, can have a variety of different profiles. Inside theannular space 19 that is formed between the inner shaft 2 b and theouter shaft 2 a, there are three separate helical fluid channels 5 a, b,c. Between the individual fluid channels 5 a, b, c, also in the annularspace 19, there are likewise helical webs 20 a, b, c. Each fluid channel5 a, b, c has a respective fluid entrance aperture 21 a, b, c on theshaft 2 and a respective fluid discharge opening 23 a, b, c on theforward end 22 of the shaft 2 provided to hold the milling head 3. Thefluid channels 5 a, b, c are particularly well suited to feed cooinglubricant to the milling head 3 in the form of the delivery of a minimumamount of lubricant. For the feed of the fluid under pressure, a smallcross section of the fluid channels 5 a, b, c in comparison to the totalcross section of the shaft 2 is sufficient. The largest part of thecross section surface F of the shaft 2 is available for the evacuationof the chips. The term “cross section surface F” as used here means thecross section surface of the shaft 2 that the shaft has on its forwardend 22, immediately adjacent to the milling head 3. The diameter D_(K)of the chip evacuation channel 11, which is defined by the insidediameter of the inner shaft 2 b, is more than 90% of the shaft diameterD_(S), which is defined by the outside diameter of the outer shaft 2 ain the area of its forward end 22. In this manner, a high mass flow ofchips and gas, in particular air, optionally mixed with coolinglubricant, can flow through the chip evacuation channel 11.

FIGS. 4A-E, 5A-E and 6A-E show various realizations of milling heads 3a, 3 b, 3 c, which are manufactured in one or more pieces from a cuttingmaterial, in particular cemented carbide, hard metal, cermet or ceramic,in particular with PKD [polycrystalline diamond] and CBN[polycrystalline cubical boron nitride], and can be connected with ashaft 2 as illustrated in FIGS. 3A-E with a milling cutter 1, inparticular by soldering. The milling heads 3 a, 3 b, 3 c are suitablefor different types of milling work, in particular for circular milling.In circular milling, the milling cutter 1 rotates around thelongitudinal axis A of the tool and simultaneously the axis A rotatesaround an additional axis which is parallel to its own axis. In thismanner, it is possible to create a boring, the diameter of which isgreater than the diameter D_(F) of the milling head 3 a, 3 b, 3 c.Therefore a multiplicity of borings with different diameters can be madewith a comparatively small number of milling cutters 1. The circularmilling has the advantage over the creation of a boring with a boringtool that during the metal removal, only short chips are formed, whichcan be easily removed from the site of the machining.

The milling head 3 a illustrated in FIG. 4A-E has five lobes or fivecutting edges with five face cutting edges 7 and five peripheral cuttingedges 9. Four of the five face cutting edges 7 are realized in the formof short cutting edges, while one of the face cutting edges 7 isrealized in the form of a long cutting edge 25, which in contrast to theshort cutting edges 24 extends from the edge 15 of the milling head 3 abeyond the longitudinal axis of the tool or the short axis A. Theperipheral cutting edges 9 in the illustrated exemplary embodiment havea notched shape with, adjacent to the corner cutting edge 8, a forwardcutting area 9 a which encloses the peripheral cutting edge angle α ofapproximately 30° with the longitudinal axis A of the cutter, and with arear cutting area 9 b which runs parallel to the longitudinal axis A ofthe tool. The fact that the forward cutting area 9 a is oriented at anangle with respect to the longitudinal axis A of the tool achieves aparticular positive cutting geometry, in particular on the cornercutting edge 8. As a result, in particular for the machining of lightalloys, metal removing operations can be carried out with a high surfacequality on the machined workpiece and with low cutting forces. Theeffect achieved with the diagonal positioning of the forward cuttingarea 9 a of the peripheral cutting edge 9 is comparable to the effectachieved with the diagonal positioning of the corner cutting edge 7 b ofthe face cutting edge 7, whereby both effects can be realizedsimultaneously on a milling head 3, 3 a so that they reinforce eachother.

The milling head 3 a, in a plan view (FIG. 4A, view from above), has afive-part aperture area 26 which corresponds to the number of facecutting edges, through which area the chips formed can be removed to thechip evacuation channel 11. The size of the aperture surface 26 variesalong the axis A of the milling cutter 1, although in all cases itequals at least 35% of the cross section surface F of the shaft 2. Theheight H_(F) of the milling head is less than 50% of the diameter D_(F)of the milling head. Chips formed are thereby introduced into the chipevacuation channel 11 after traveling only a very short distance. Thetapered area 17 of the milling head 3 a has a slightly conicalconfiguration, to facilitate the insertion of the milling head 3 a intothe appropriately shaped shaft 2 (FIG. 3A-E).

The milling head 3 b illustrated in FIGS. 5A-5E is realized with threelobes and otherwise corresponds to the milling head 3 a illustrated inFIGS. 4A-4E. The milling head 3 c illustrated in FIGS. 6A-6H is anadditional realization of a three-lobed milling head with a particularlylarge aperture area 26. The milling head 3 c has a depression 40 in thearea of the axis A, on its end surface 6. The peripheral step 16 isparticularly pronounced in the milling head 3 c. In particular, the sideview in FIG. 6C shows that the face cutting edges 7 fall off to someextend from the edge 15 of the milling head 3 c toward the axis A, i.e.the face cutting edges 7 at the respective corner cutting edge 8 are atthe maximum axial distance from the shaft 2. The angles formed at thecutting edges 7, 9, namely the axial clearance angle α_(a), the axialcutting wedge angle β_(a), and the axial rank angle γ_(a) on the facecutting edge 7, as well as the radial clearance angle α_(r), the radialcutting wedge angle β_(r) and the radial rake angle γ_(r) on theperipheral cutting edge 9 are shown in FIGS. 6G and 6H. From thisconfiguration, it follows that the axial rake angle γ_(a) is greaterthan the radial rake angle γ_(r), which makes possible a particularlyeasy removal of chips in the axial direction.

FIG. 7 and FIGS. 8A-8D show a milling cutter 1 which is chucked in ahydraulic expansion chuck 27 or in a chucking and feeding device 28. Inthe illustrated exemplary embodiment, the milling cutter 1 can bechucked in the chucking and feeding device 28 without a hydraulicchucking mechanism, although the integration of such a hydraulicchucking mechanism is also possible. The chucking and supply device 28makes possible both a feed of fluids to the fluid channels 5 a, b, c aswell as a sucking of chips and optionally fluid from the suction opening12. For this purpose the chucking and feed device 28 has a fluid feedpipe 29 and a suction funnel 30, which can be connected to removal ordisposal devices which are not shown in the drawings.

Compressed air and/or cooling lubricant can be fed through the fluidfeed pipe 29 to the milling cutter 1 by means of a coolant ring 31.Alternatively, separate fluid feed pipes 29 can also be provided for thecompressed air feed on one hand and the cooling lubricant feed on theother hand. In all cases, the mass flow fed through the fluid feed pipe29 to the milling cutter 1—not taking the mass of the chips intoconsideration—is approximately equal to the mass current evacuated viathe suction funnel 30, to which an underpressure can be applied, fromthe suction opening 12. In this manner, it can be ensured that the chipsare removed in their entirety and immediately after their formationthrough the internal chip evacuation channel 11.

The chucking and feed device 28 has a bearing housing 32 in which, bymeans of a forward ball bearing 33 and a rear ball bearing 34, a basereceptacle 35 which holds the shaft 2 concentrically, is mounted so thatit can rotate. The essentially rotationally symmetrical base receptacle35 has a multiplicity of openings to make it possible to feed compressedair and/or cooling lubricant and to remove the chips to and from themilling cutter respectively. On the front side of the bearing housing 32facing the milling head 3, to chuck and secure the base receptacle 35and the shaft 2 in position, there are an internal retaining nut 36, anexternal retaining nut 37, two drive pins 38 and a circlip 39.

One feature or aspect of an embodiment is believed at the time of thefiling of this patent application to possibly reside broadly in amilling cutter which can be rotated around a tool longitudinal axis,with a sleeve-shaped shaft with an internal chip evacuation channel thatis located essentially symmetrical to the longitudinal axis of the tooland a suction aperture, a milling head held so that it is coaxial to thelongitudinal axis of the tool and to the shaft on the shaft, with anface cutting edge and a peripheral cutting edge as cutting edges,whereby at least one cutting edge on the periphery of the milling headforms a positive rake angle.

Another feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the rake angle on theperiphery of the milling head is at least 10°.

Yet another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that both the rake angle ofthe face cutting edge and the rake angle of the peripheral cutting edgeon the periphery of the milling head is at least 10°.

Still another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the milling head isformed in one piece from a cutting material.

A further feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the diameter of the shaftis smaller than the diameter of the milling head at least in an areathat borders the milling head.

Another feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the milling head has anaperture surface for the removal of chips into the chip evacuationchannel, which amounts to at least 35% of the cross section surface ofthe shaft.

Yet another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the height of the millinghead is a maximum of 50% of the diameter of the milling head.

Still another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the milling head isrealized with at least three lobes.

A further feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the face cutting edgeextends from one edge of the milling head to beyond the longitudinalaxis of the tool.

Another feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the peripheral cuttingedge is adjacent to a corner cutting edge on the face cutting edge.

Yet another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the corner cutting edge,with reference to the direction of the longitudinal axis of the tool, isthe part of the milling head that is axially the farthest from theshaft.

Still another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the peripheral cuttingedge encloses an angle of twist (γ) of at least 10° with thelongitudinal axis of the tool.

A further feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the milling head has aperipheral step, adjacent to which in the direction toward the shaft isa tapered area of the milling head.

Another feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the peripheral cuttingedge is adjacent to the peripheral step.

Yet another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the shaft is realizedwith a double wall, with an inner shaft and an outer shaft.

Still another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by a fluid feed opening located laterallyon the outer shaft.

A further feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by a helical fluid channel between theinner shaft and the outer shaft.

Another feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the diameter of the chipevacuation channel is at least 75% of the shaft diameter.

Yet another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the wall thickness of theouter shaft is a maximum of 10% of the shaft diameter.

Still another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the wall thickness of theinner shaft is a maximum of 10% of the shaft diameter.

A further feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the wall thickness of theinner shaft is less than the wall thickness of the outer shaft.

Another feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter which can be rotated around a tool longitudinal axis,with a sleeve-shaped shaft with an internal chip evacuation channel thatis located essentially symmetrical to the longitudinal axis of the tooland a suction aperture, a milling head held so that it is coaxial to thelongitudinal axis of the tool and to the shaft on the shaft, with anface cutting edge and a peripheral cutting edge as cutting edges,whereby at least one cutting edge on the periphery of the milling headforms a positive rake angle, characterized by the fact that the shaft isrealized with a double wall, with an inner shaft and an outer shaft.

Yet another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the rake angle on theperiphery of the milling head is at least 10°.

Still another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that both the rake angle ofthe face cutting edge and the rake angle of the peripheral cutting edgeon the periphery of the milling head is at least 10°.

A further feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in amilling cutter, characterized by the fact that the peripheral cuttingedge encloses an angle of twist of at least 10° with the longitudinalaxis of the tool.

Another feature or aspect of an embodiment is believed at the time ofthe filing of this patent application to possibly reside broadly in anend milling cutter configured to mill light metals, said end millingcutter having a central longitudinal axis about which said end millingcutter is to be rotated, said end milling cutter comprising: asleeve-shaped shaft being disposed coaxially with respect to saidcentral longitudinal axis; an internal channel disposed in said shaft;said internal channel being configured to receive and guide light metalchips produced during a cutting process; a suction device beingoperatively connected to said internal channel; said suction devicebeing configured and disposed to create a suction force in said internalchannel to suck light metal chips produced during a light metal cuttingprocess through said internal channel; a milling head being connected toan end of said shaft and being disposed coaxially with respect to saidcentral longitudinal axis; said milling head comprising: an end facedisposed at an end of said end milling cutter and facing away from saidshaft; a peripheral side surface disposed about the perimeter of saidmilling head; a cutting structure being configured to cut a light metalobject in a cutting process; and said cutting structure comprising: aface cutting edge being disposed to lie in said end face of said millinghead; a peripheral cutting edge being disposed to lie in said peripheralside surface of said milling head; and at least one of said cuttingedges forms a positive rake angle (γ_(a), γ_(r)).

Yet another feature or aspect of an embodiment is believed at the timeof the filing of this patent application to possibly reside broadly in amethod of milling a light metal, such as magnesium, with an end millingcutter configured to mill light metals, said end milling cutter having acentral longitudinal axis about which said end milling cutter is to berotated, said end milling cutter comprising: a sleeve-shaped shaft beingdisposed coaxially with respect to said central longitudinal axis; aninternal channel disposed in said shaft; said internal channel beingconfigured to receive and guide light metal chips produced during acutting process; a suction device being operatively connected to saidinternal channel; said suction device being configured and disposed tocreate a suction force in said internal channel to suck light metalchips produced during a light metal cutting process through saidinternal channel; a milling head being connected to an end of said shaftand being disposed coaxially with respect to said central longitudinalaxis; said milling head comprising: an end face disposed at an end ofsaid end milling cutter and facing away from said shaft; a peripheralside surface disposed about the perimeter of said milling head; acutting structure being configured to cut a light metal object in acutting process; and said cutting structure comprising: a face cuttingedge being disposed to lie in said end face of said milling head; aperipheral cutting edge being disposed to lie in said peripheral sidesurface of said milling head; and at least one of said cutting edgesforms a positive rake angle (γ_(a), γ_(r)) said method comprising thesteps of: cutting a light metal, such as magnesium, with said cuttingedges of said end milling cutter; sucking chips into said internalchannel with said sucking device to essentially prevent combustion oflight metal chips, such as magnesium; and essentially preventingcombustion of light metal chips, such as magnesium.

The components disclosed in the various publications, disclosed orincorporated by reference herein, may possibly be used in possibleembodiments of the present invention, as well as equivalents thereof.

The purpose of the statements about the technical field is generally toenable the Patent and Trademark Office and the public to determinequickly, from a cursory inspection, the nature of this patentapplication. The description of the technical field is believed, at thetime of the filing of this patent application, to adequately describethe technical field of this patent application. However, the descriptionof the technical field may not be completely applicable to the claims asoriginally filed in this patent application, as amended duringprosecution of this patent application, and as ultimately allowed in anypatent issuing from this patent application. Therefore, any statementsmade relating to the technical field are not intended to limit theclaims in any manner and should not be interpreted as limiting theclaims in any manner.

The appended drawings in their entirety, including all dimensions,proportions and/or shapes in at least one embodiment of the invention,are accurate and are hereby included by reference into thisspecification.

The background information is believed, at the time of the filing ofthis patent application, to adequately provide background informationfor this patent application. However, the background information may notbe completely applicable to the claims as originally filed in thispatent application, as amended during prosecution of this patentapplication, and as ultimately allowed in any patent issuing from thispatent application. Therefore, any statements made relating to thebackground information are not intended to limit the claims in anymanner and should not be interpreted as limiting the claims in anymanner.

Some examples of reamers that may be utilized or adapted for use in atleast one possible embodiment of the present invention may be found inthe following U.S. Pat. Nos. 6,202,768 B1, issued to Lindgren et al. onMar. 20, 2001; 6,112,835, issued to Grafe et al. on Sep. 5, 2000;6,076,618, issued to Åsberg on Jun. 20, 2000; 5,551,812, issued toBasteck on Sep. 3, 1996; 5,499,896, issued to Cafarelli on Mar. 19,1996; 5,354,155, issued to Adams on Oct. 11, 1994; 5,328,304, issued toKress et al. on Jul. 12, 1994; 5,238,335, issued to Nomura on Aug. 24,1993; 5,217,333, issued to Hunt on Jun. 8, 1993; 5,190,113, issued toHawrylak on Mar. 2, 1993; 5,163,790, issued to Vig on Nov. 17, 1992;5,149,233, issued to Kress et al. on Sep. 22, 1992; 4,936,721, issued toMeyer on Jun. 26, 1990; 4,795,289, issued to Potemkin on Jan. 3, 1989;4,792,264, issued to Kress et al. on Dec. 20, 1988; 4,705,435, issued toChristoffel on Nov. 10, 1987; 4,480,704, issued to May et al. on Nov. 6,1984; 4,452,307, issued to Horton on Jun. 5, 1984; 4,350,204, issued toHorton on Sep. 21, 1982; 4,182,425, issued to Garrett on Jan. 8, 1980;4,040,765, issued to Vig on Aug. 9, 1977; and 4,014,622, issued to Lotzon Mar. 29, 1977.

All, or substantially all, of the components and methods of the variousembodiments may be used with at least one embodiment or all of theembodiments, if more than one embodiment is described herein.

The purpose of the statements about the object or objects is generallyto enable the Patent and Trademark Office and the public to determinequickly, from a cursory inspection, the nature of this patentapplication. The description of the object or objects is believed, atthe time of the filing of this patent application, to adequatelydescribe the object or objects of this patent application. However, thedescription of the object or objects may not be completely applicable tothe claims as originally filed in this patent application, as amendedduring prosecution of this patent application, and as ultimately allowedin any patent issuing from this patent application. Therefore, anystatements made relating to the object or objects are not intended tolimit the claims in any manner and should not be interpreted as limitingthe claims in any manner.

All of the patents, patent applications and publications recited herein,and in the Declaration attached hereto, are hereby incorporated byreference as if set forth in their entirety herein.

Some examples of milling cutters that may be utilized or adapted for usein at least one possible embodiment of the present invention may befound in the following U.S. Pat. Nos. 6,231,281 B1, issued to Nishikawaon May 15, 2001; 6,220,795 B1, issued to Matthews on Apr. 24, 2001;6,217,262 B1, issued to Wright on Apr. 17, 2001; 6,176,648 B1, issued toMizutani on Jan. 23, 2001; 6,158,927, issued to Cole et al. on Dec. 12,2000; 6,146,059, issued to Rohr on Nov. 14, 2000; 6,109,838, issued toRiviere on Aug. 29, 2000; 6,042,308, issued to Schmitt on Mar. 28, 2000;5,967,706, issued to Hughes, Jr. on Oct. 19, 1999; 5,957,628, issued toBentjens et al. on Sep. 28, 1999; 5,934,842, issued to Gupta on Aug. 10,1999; 5,919,008, issued to Shimomura on Jul. 6, 1999; 5,899,642, issuedto Berglow et al. on May 4, 1999; 5,868,529, issued to Rothballer et al.on Feb. 9, 1999; 5,848,858, issued to Jager et al. on Dec. 15, 1998;5,820,308, issued to Hoefler on Oct. 13, 1998; 5,762,452, issued to Minaon Jun. 9, 1998; 5,672,031, issued to Oles on Sep. 30, 1997; 5,542,795,issued to Mitchell on Aug. 6, 1996; 5,542,794, issued to Smith et al. onAug. 6, 1996; 5,529,439, issued to Werner et al. on Jun. 25, 1996;4,990,035, issued to Scheuch et al. on Feb. 5, 1991; 4,938,638, issuedto Hessman et al. on Jul. 3, 1990; 4,930,949, issued to Giessler on Jun.5, 1990; 4,848,978, issued to Keritsis on Jul. 18, 1989; 4,799,838,issued to Kubo et al. on Jan. 24, 1989; 4,789,273, issued to Wiacek etal. on Dec. 6, 1988; 4,729,697, issued to Lacey on Mar. 8, 1988;4,728,228, issued to Okunishi et al. on Mar. 1, 1988; 4,627,771, issuedto Kieninger on Dec. 9, 1986; 4,623,284, issued to Greiff on Nov. 18,1986; 4,533,282, issued to Lindlar et al. on Aug. 6, 1985; 4,519,731,issued to Jester et al. on May 28, 1985; 4,493,594, issued to Okada onJan. 15, 1985; 4,461,602, issued to Zettl on Jul. 24, 1984; 4,359,299,issued to Sagarian on Nov. 16, 1982; 4,204,787, issued to McCray et al.on May 27, 1980; 4,097,174, issued to Heinlein on Jun. 27, 1978;4,093,392, issued to Hopkins on Jun. 6, 1978; 4,061,076, issued toRobertson on Dec. 6, 1977; 4,050,129, issued to Jester et al. on Sep.27, 1977; and 4,050,128, issued to Lange on Sep. 27, 1977.

The summary is believed, at the time of the filing of this patentapplication, to adequately summarize this patent application. However,portions or all of the information contained in the summary may not becompletely applicable to the claims as originally filed in this patentapplication, as amended during prosecution of this patent application,and as ultimately allowed in any patent issuing from this patentapplication. Therefore, any statements made relating to the summary arenot intended to limit the claims in any manner and should not beinterpreted as limiting the claims in any manner.

It will be understood that the examples of patents, published patentapplications, and other documents which are included in this applicationand which are referred to in paragraphs which state “Some examples of .. . which may possibly be used in at least one possible embodiment ofthe present application . . . ” may possibly not be used or useable inany one or more embodiments of the application.

The sentence immediately above relates to patents, published patentapplications and other documents either incorporated by reference or notincorporated by reference.

All of the patents, patent applications or patent publications, whichwere cited in the International Search Report dated Sep. 26, 2003,and/or cited elsewhere are hereby incorporated by reference as if setforth in their entirety herein as follows: U.S. Pat. No. 5,759,185; U.S.Pat. No. 2,437,668; JP 2002166320; JP 62199339; DE 3143847; U.S. Pat.No. 5,433,655; DE 19512401; and U.S. Pat. No. 4,543,019.

The corresponding foreign and international patent publicationapplications, namely, Federal Republic of Germany Patent Application No.102 22 040.9, filed on May 17, 2002, having inventors Dirk KAMMERMEIERand Peter MERGENTHALER, and DE-OS 102 22 040.9 and DE-PS 102 22 040.9,and International Application No. PCT/EP03/05191, filed on May 16, 2003,having WIPO Publication No. WO 03/097283 A1 and inventors DirkKAMMERMEIER and Peter MERGENTHALER, as well as their publishedequivalents, and other equivalents or corresponding applications, ifany, in corresponding cases in the Federal Republic of Germany andelsewhere, and the references and documents cited in any of thedocuments cited herein, such as the patents, patent applications andpublications, are hereby incorporated by reference as if set forth intheir entirety herein.

All of the references and documents, cited in any of the documents citedherein, are hereby incorporated by reference as if set forth in theirentirety herein. All of the documents cited herein, referred to in theimmediately preceding sentence, include all of the patents, patentapplications and publications cited anywhere in the present application.

The description of the embodiment or embodiments is believed, at thetime of the filing of this patent application, to adequately describethe embodiment or embodiments of this patent application. However,portions of the description of the embodiment or embodiments may not becompletely applicable to the claims as originally filed in this patentapplication, as amended during prosecution of this patent application,and as ultimately allowed in any patent issuing from this patentapplication. Therefore, any statements made relating to the embodimentor embodiments are not intended to limit the claims in any manner andshould not be interpreted as limiting the claims in any manner.

The details in the patents, patent applications and publications may beconsidered to be incorporable, at applicant's option, into the claimsduring prosecution as further limitations in the claims to patentablydistinguish any amended claims from any applied prior art.

The purpose of the title of this patent application is generally toenable the Patent and Trademark Office and the public to determinequickly, from a cursory inspection, the nature of this patentapplication. The title is believed, at the time of the filing of thispatent application, to adequately reflect the general nature of thispatent application. However, the title may not be completely applicableto the technical field, the object or objects, the summary, thedescription of the embodiment or embodiments, and the claims asoriginally filed in this patent application, as amended duringprosecution of this patent application, and as ultimately allowed in anypatent issuing from this patent application. Therefore, the title is notintended to limit the claims in any manner and should not be interpretedas limiting the claims in any manner.

A description of what is meant by a “positive rake angle” may possiblybe found in a printed excerpt, specifically chapter 2, of “Cutting ToolApplications” by George Schneider, Jr. CmfgE, which excerpt waspublished in the February, 2001 issue of “Tooling and Production”magazine, which is a publication of Tooling and Production, located at6001 Cochran Rd., Suite 104, Solon, Ohio 44139, and Nelson Publishing,Inc., located at 2500 Tamiami Trail North, Nokomis, Fla. 34275. Theabove published excerpt is incorporated by reference as if set forth inits entirety herein.

The abstract of the disclosure is submitted herewith as required by 37C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b):

-   -   A brief abstract of the technical disclosure in the        specification must commence on a separate sheet, possibly        following the claims, under the heading “Abstract of the        Disclosure.” The purpose of the abstract is to enable the Patent        and Trademark Office and the public generally to determine        quickly from a cursory inspection the nature and gist of the        technical disclosure. The abstract shall not be used for        interpreting the scope of the claims.        Therefore, any statements made relating to the abstract are not        intended to limit the claims in any manner and should not be        interpreted as limiting the claims in any manner.

Some examples of milling cutters, such as the WIDIA M680 Series,manufactured by Kennametal Inc., 1600 Technology Way, Latrobe, Pa.,15650, and components thereof that may be utilized or adapted for use inat least one possible embodiment of the present invention may be foundin the following publications: “WIDIA” product catalog, published in2003; “Universal End Milling—Mill 1 NGE-A Universal Face Milling—KSOM”product catalog 3053; and “High-Performance Milling Cutters forHigh-Temp Alloys and Stainless Steels” product catalog 2052; allpublished by Kennametal Inc., and/or by at least one of the divisions orsubsidiaries thereof. These publications are incorporated by referenceas if set forth in their entirety herein.

The embodiments of the invention described herein above in the contextof the preferred embodiments are not to be taken as limiting theembodiments of the invention to all of the provided details thereof,since modifications and variations thereof may be made without departingfrom the spirit and scope of the embodiments of the invention.

AT LEAST PARTIAL NOMENCLATURE

-   1 Milling cutter-   2 Shank-   2 a Outer shank-   2 b Inner shank-   3 a, b, c Milling head-   4 Contact area-   5 a,b,c Fluid channel-   6 Face side-   7 Face cutting edge,-   7 a Radial cutting edge-   7 b Beveled cutting edge-   8 Corner cutting edge-   9 Peripheral cutting edge-   9 a Forward cutting area-   9 b Rear cutting area-   10 Gap-   11 Chip evacuation channel-   12 Suction aperture-   13 Shaft end-   14 Thicker portion-   15 Periphery-   16 Peripheral step-   17 Tapered area-   18 Forward area-   19 Annular space-   20 a,b,c Web-   21 a,b,c Fluid entrance aperture-   22 Forward end-   23 a,b,c Fluid exit aperture-   24 Short cutting edge-   25 Long cutting edge-   26 Aperture surface-   27 Hydraulic expansion chuck-   28 Chucking and feed device-   29 Fluid feed pipes-   30 Suction funnel-   31 Coolant ring-   32 Bearing casing-   33 Ball bearing-   34 Ball bearing-   35 Base receptacle-   36 Retaining nut-   37 Retaining nut-   38 Driving pin-   39 Circlip-   40 Depression    Symbols-   γ Angle of twist-   α_(a) Axial clearance angle-   β_(a) Axial cutting wedge angle-   γ_(a) Axial rake angle-   α_(r) Radial clearance angle-   β_(r) Radial cutting wedge angle-   γ_(r) Radial rake angle-   A Longitudinal axis of tool-   D_(K) Diameter of chip evacuation channel-   D_(S) Diameter of shaft-   D Diameter of milling head-   F Cross section surface-   H_(F) Height of milling head-   W_(A) Wall thickness-   W_(B) Wall thickness

1-20. (canceled)
 21. A method of milling a magnesium workpiece with anend milling cutter comprising a central longitudinal axis about whichsaid end milling cutter is to be rotated, said end milling cuttercomprising: a rotatable shaft comprising an internal channel disposed insaid shaft; said internal channel being configured to receive and guidechips produced during a cutting process; said internal channel beingconfigured to be operatively connected to a suction device configured tocreate a suction force in said internal channel to suck chips producedduring a cutting process through said internal channel; a milling headbeing disposed at an end of said shaft and being connected to said shaftto be driven and rotated by said shaft in a cutting operation; and saidmilling head comprising: an end face being disposed at an end of saidend milling cutter and facing away from said shaft; said end face beingsubstantially orthogonal to the longitudinal axis; said end facecomprising a substantially flat solid portion being disposedsubstantially in a plane; a peripheral side surface disposed about theperimeter of said milling head; a cutting structure being configured tocut an object in a cutting process; and said cutting structurecomprising: a face cutting edge being disposed to lie in said end faceand substantially in the plane of said end face of said milling head; aperipheral cutting edge being disposed to lie in said peripheral sidesurface of said milling head; at least one of said cutting edges beingconfigured to form a positive rake angle; upon said face cutting edgeforming a positive rake angle, said face cutting edge being configuredas follows: (a) said face cutting edge and said peripheral side surfaceforming an angle, across a solid portion of said end face between saidface cutting edge and said peripheral side surface, at the intersectionof said face cutting edge and said peripheral side surface; said facecutting edge angle comprising an acute angle configured to form apositive rake angle; upon said peripheral cutting edge forming apositive rake angle said peripheral cutting edge being configured asfollows: (b) said peripheral cutting edge and said end face forming anangle, across a solid portion of said peripheral side surface betweensaid peripheral cutting edge and said end face, at the intersection ofsaid peripheral cutting edge and said end face; and said peripheralcutting edge angle comprising an acute angle configured to form apositive rake angle; said method comprising the steps of: rotating saidrotatable shaft and driving and rotating said milling head; creating asuction force in said internal channel using a suction deviceoperatively connected to said internal channel; bringing said millinghead into contact with the magnesium workpiece; cutting the magnesiumworkpiece with said cutting edges of said end milling cutter andproducing magnesium chips; and sucking the magnesium chips into andthrough said internal channel in said shaft and conducting the magnesiumchips away from the magnesium workpiece to essentially preventcombustion of the magnesium chips; and essentially preventing combustionof the magnesium chips.
 22. The method according to claim 21, wherein:both the rake angle of said face cutting edge and the rake angle of saidperipheral cutting edge are configured to form positive rake angles; andat least one of the rake angle of said face cutting edge and the rakeangle of said peripheral cutting edge is at least 10°.
 23. The methodaccording to claim 22, wherein: said milling head is formed in one piecefrom a cutting material; said shaft comprises a diameter; said millinghead comprises a diameter; the diameter of said shaft is smaller thanthe diameter of said milling head, at least in an area that borders saidmilling head; said milling head has an aperture surface for the removalof chips into said internal channel configured to receive and guidechips, which amounts to at least 35% of the cross section surface ofsaid shaft; and said step of sucking magnesium chips into and throughsaid internal channel in said shaft comprises sucking magnesium chipsthrough said aperture surface and into said internal channel.
 24. Themethod according to claim 23, wherein: the height of said milling headis a maximum of 50% of the diameter of said milling head; said millinghead is realized with at least three lobes; and said face cutting edgeextends from one edge of said milling head to beyond the longitudinalaxis of said end milling cutter.
 25. The method according to claim 24,wherein said milling cutter comprises at least one of (a) through (f),as follows: (a) said shaft is realized with a double wall, with an innershaft and an outer shaft; said milling cutter comprises a fluid feedopening located laterally on said outer shaft; (b) said shaft isrealized with a double wall, with an inner shaft and an outer shaft;said milling cutter comprises a helical fluid channel between said innershaft and said outer shaft; (c) said internal channel configured toreceive and guide chips comprises a diameter; the diameter of saidinternal channel configured to receive and guide chips is at least 75%of said shaft diameter; (d) said shaft is realized with a double wall,with an inner shaft and an outer shaft; the wall thickness of said outershaft is a maximum of 10% of said shaft diameter; (e) said shaft isrealized with a double wall, with an inner shaft and an outer shaft; thewall thickness of the inner shaft is a maximum of 10% of the shaftdiameter; and (f) said shaft is realized with a double wall, with aninner shaft and an outer shaft; the wall thickness of said inner shaftis less than the wall thickness of said outer shaft.
 26. The methodaccording to claim 25, wherein: said peripheral cutting edge is adjacentto a corner cutting edge on said face cutting edge; said corner cuttingedge, with reference to the direction of the longitudinal axis of saidend milling cutter, is the part of said milling head that is axially thefarthest from said shaft; said peripheral cutting edge encloses an angleof twist of at least 10° with the longitudinal axis of said end millingcutter; said milling head has a peripheral step, adjacent to which inthe direction toward said shaft is a tapered area of said milling head;said peripheral cutting edge is adjacent to said peripheral step; saidshaft is realized with a double wall, with an inner shaft and an outershaft; said milling cutter comprises a fluid feed opening locatedlaterally on said outer shaft; said milling cutter comprises a helicalfluid channel between said inner shaft and said outer shaft; saidinternal channel configured to receive and guide chips comprises adiameter; the diameter of said internal channel configured to receiveand guide chips is at least 75% of said shaft diameter; the wallthickness of said outer shaft is a maximum of 10% of said shaftdiameter; the wall thickness of said inner shaft is a maximum of 10% ofsaid shaft diameter; and the wall thickness of said inner shaft is lessthan the wall thickness of said outer shaft.
 27. A method of milling alight metal workpiece with an end milling cutter comprising a centrallongitudinal axis about which said end milling cutter is to be rotated,said end milling cutter comprising: a rotatable shaft comprising aninternal channel disposed in said shaft; said internal channel beingconfigured to receive and guide chips produced during a cutting process;said internal channel being configured to be operatively connected to asuction device configured to create a suction force in said internalchannel to suck chips produced during a cutting process through saidinternal channel; a milling head being disposed at an end of said shaftand being connected to said shaft to be driven and rotated by said shaftin a cutting operation; and said milling head comprising: an end facebeing disposed at an end of said end milling cutter and facing away fromsaid shaft; said end face being substantially orthogonal to thelongitudinal axis; said end face comprising a solid portion beingsubstantially flat; a peripheral side surface disposed about theperimeter of said milling head; a cutting structure being configured tocut an object in a cutting process; said cutting structure configured tocut in a rotational cutting direction; and said cutting structurecomprising: a face cutting edge being disposed to lie in said end faceof said milling head; a peripheral cutting edge being disposed to lie insaid peripheral side surface of said milling head; at least one of saidcutting edges being configured to form a positive rake angle; upon saidface cutting edge forming a positive rake angle, said face cutting edgebeing configured as follows: (a) said face cutting edge having a firstportion and a second portion; said first portion of said face cuttingedge disposed adjacent said peripheral side surface; said second portionof said face cutting edge disposed away from said peripheral sidesurface; said first portion of said face cutting edge being configuredto be rotationally ahead of, in the rotational cutting direction, toprecede rotationally, said second portion of said face cutting edgeduring use; upon said peripheral cutting edge forming a positive rakeangle, said peripheral cutting edge being configured as follows: (b)said peripheral cutting edge having a first portion and a secondportion; said first portion of said peripheral cutting edge disposedadjacent said end face; said second portion of said peripheral cuttingedge disposed away from said end face; and said first portion of saidperipheral cutting edge being configured to be rotationally ahead of, toprecede rotationally, said second portion of said peripheral cuttingedge during use; said method comprising the steps of: rotating saidrotatable shaft and driving and rotating said milling head; creating asuction force in said internal channel using a suction deviceoperatively connected to said internal channel; bringing said millinghead into contact with the light metal workpiece; cutting the lightmetal workpiece with said cutting edges of said end milling cutter andproducing light metal chips; and sucking the light metal chips into andthrough said internal channel in said shaft and conducting the lightmetal chips away from the light metal workpiece.
 28. The methodaccording to claim 27, wherein at least one of the rake angle of saidface cutting edge and the rake angle of said peripheral cutting edge isat least 10°.
 29. The method according to claim 28, wherein both therake angle of said face cutting edge and the rake angle of saidperipheral cutting edge are configured to form positive rake angles. 30.The method according to claim 29, wherein said milling cutter comprisesat least one of (a) and (b): (a) said milling head is formed in onepiece from a cutting material; said shaft comprises an outer diameter;said milling head comprises an outer diameter; the outer diameter ofsaid shaft is smaller than said outer diameter of said milling head, atleast in an area that borders said milling head; said milling head hasan aperture surface for the removal of chips into said internal channelconfigured to receive and guide chips, which comprises at least 35% ofthe cross section surface of the outer diameter of said shaft; and saidstep of sucking light metal chips into and through said internal channelin said shaft comprises sucking light metal chips through said aperturesurface and into said internal channel; (b) the height of said millinghead is a maximum of 50% of the diameter of said milling head; saidmilling head is realized with at least three lobes; and said facecutting edge extends from one edge of said milling head to beyond thelongitudinal axis of said end milling cutter.
 31. The method accordingto claim 30, wherein said milling cutter comprises at least one of (a)through (h), as follows: (a) said peripheral cutting edge is adjacent toa corner cutting edge on said face cutting edge; said corner cuttingedge, with reference to the direction of the longitudinal axis of saidend milling cutter, is the part of said milling head that is axially thefarthest from said shaft; and said peripheral cutting edge encloses anangle of twist of at least 10° with the longitudinal axis of said endmilling cutter; (b) said milling head has a peripheral step, adjacent towhich in the direction toward said shaft is a tapered area of saidmilling head; said peripheral cutting edge is adjacent to saidperipheral step; and said shaft is realized with a double wall, with aninner shaft and an outer shaft; (c) said shaft is realized with a doublewall, with an inner shaft and an outer shaft; said milling cuttercomprises a fluid feed opening located laterally on said outer shaft;(d) said shaft is realized with a double wall, with an inner shaft andan outer shaft; said milling cutter comprises a helical fluid channelbetween said inner shaft and said outer shaft; (e) said internal channelconfigured to receive and guide chips comprises a the diameter; thediameter of said internal channel configured to receive and guide chipsis at least 75% of said shaft diameter; (f) said shaft is realized witha double wall, with an inner shaft and an outer shaft; the wallthickness of said outer shaft is a maximum of 10% of said shaftdiameter; (g) said shaft is realized with a double wall, with an innershaft and an outer shaft; the wall thickness of said inner shaft is amaximum of 10% of said shaft diameter; and (h) said shaft is realizedwith a double wall, with an inner shaft and an outer shaft; the wallthickness of said inner shaft is less than the wall thickness of saidouter shaft.
 32. The method according to claim 31, wherein: saidperipheral cutting edge is adjacent to a corner cutting edge on saidface cutting edge; said corner cutting edge, with reference to thedirection of the longitudinal axis of said end milling cutter, is thepart of said milling head that is axially the farthest from said shaft;said peripheral cutting edge encloses an angle of twist of at least 10°with the longitudinal axis of said end milling cutter; said milling headhas a peripheral step, adjacent to which in the direction toward saidshaft is a tapered area of said milling head; said peripheral cuttingedge is adjacent to said peripheral step; said shaft is realized with adouble wall, with an inner shaft and an outer shaft; said milling cuttercomprises a fluid feed opening located laterally on said outer shaft;said milling cutter comprises a helical fluid channel between said innershaft and said outer shaft; said internal channel configured to receiveand guide chips comprises a diameter; the diameter of said internalchannel configured to receive and guide chips is at least 75% of saidshaft diameter; the wall thickness of said outer shaft is a maximum of10% of said shaft diameter; the wall thickness of said inner shaft is amaximum of 10% of said shaft diameter; and the wall thickness of saidinner shaft is less than the wall thickness of said outer shaft.
 33. Amethod of milling a workpiece with a milling cutter comprising a centrallongitudinal axis about which said milling cutter is to be rotated, saidmilling cutter comprising: a rotatable shaft comprising an internalchannel disposed in said shaft; said internal channel being configuredto receive and guide chips produced during a cutting process; saidinternal channel being configured to be operatively connected to asuction device being configured to create a suction force in saidinternal channel to suck chips produced during a cutting process throughsaid internal channel; a milling head being disposed at an end of saidshaft and being connected to said shaft to be driven and rotated by saidshaft in a cutting operation; and said milling head comprising: an endsurface being disposed at an end of said milling cutter and disposedaway from said shaft; said end surface being substantially transverse tothe longitudinal axis; said end surface comprising a solid portion; aperipheral side surface being disposed about the perimeter of saidmilling head; a cutting structure being configured to cut an object in acutting process; and said cutting structure comprising: an end cuttingedge being disposed to lie in said end surface; and a peripheral cuttingedge being disposed to lie in said peripheral side surface of saidmilling head; said method comprising the steps of: rotating saidrotatable shaft and driving and rotating said milling head; creating asuction force in said internal channel using a suction deviceoperatively connected to said internal channel; bringing said millinghead into contact with the workpiece; cutting the workpiece with saidcutting edges of said end milling cutter and producing chips; andsucking the chips into and through said internal channel in said shaftand conducting the chips away from the workpiece.
 34. The methodaccording to claim 33, wherein: at least one of said cutting edges isconfigured to form a positive rake angle; upon said end cutting edgeforming a positive rake angle, said end cutting edge being configured asfollows: (a) said end cutting edge and said peripheral side surfaceforming an angle, across a solid portion of said end surface betweensaid end cutting edge and said peripheral side surface; said end cuttingedge angle comprising an acute angle; said end cutting edge acute anglebeing configured to dispose said end cutting edge at a positive rakeangle; and upon said peripheral cutting edge forming a positive rakeangle said peripheral cutting edge being configured as follows: (b) saidperipheral cutting edge and said end surface forming an angle, across asolid portion of said peripheral side surface between said peripheralcutting edge and said end surface; said peripheral cutting edge anglecomprising an acute angle to form a positive rake angle; and saidperipheral cutting edge acute angle being configured to dispose saidperipheral cutting edge at a positive rake angle.
 35. The methodaccording to claim 34, wherein: said end surface comprises an end facedisposed to face away from said shaft; said solid portion of said endface is disposed to lie substantially in a plane; said end cutting edgecomprises a face cutting edge disposed to lie substantially in the planeof said end face; at least one of the rake angle of said face cuttingedge and the rake angle of said peripheral cutting edge is at least 10°.36. The method according to claim 35, wherein: said milling head isformed in one piece from a cutting material; said shaft comprises adiameter; said milling head comprises a diameter; the diameter of saidshaft is smaller than the diameter of said milling head, at least in anarea that borders said milling head; said milling head has an aperturesurface for the removal of chips into said internal channel configuredto receive and guide chips, which amounts to at least 35% of the crosssection surface of said shaft; and said step of sucking chips into andthrough said internal channel in said shaft comprises sucking chipsthrough said aperture surface and into said internal channel.
 37. Themethod according to claim 36, wherein: the height of said milling headis a maximum of 50% of the diameter of said milling head; said millinghead is realized with at least three lobes; and said face cutting edgeextends from one edge of said milling head to beyond the longitudinalaxis of said milling cutter.
 38. The method according to claim 37,wherein both the rake angle of said face cutting edge and the rake angleof said peripheral cutting edge are configured to form positive rakeangles.
 39. The method according to claim 38, wherein said millingcutter comprises at least one of (a) through (h), as follows: (a) saidperipheral cutting edge is adjacent to a corner cutting edge on saidface cutting edge; said corner cutting edge, with reference to thedirection of the longitudinal axis of said milling cutter, is the partof said milling head that is axially the farthest from said shaft; andsaid peripheral cutting edge encloses an angle of twist of at least 10°with the longitudinal axis of said milling cutter; (b) said milling headhas a peripheral step, adjacent to which in the direction toward saidshaft is a tapered area of said milling head; said peripheral cuttingedge is adjacent to said peripheral step; said shaft is realized with adouble wall, with an inner shaft and an outer shaft; (c) said shaft isrealized with a double wall, with an inner shaft and an outer shaft;said milling cutter comprises a fluid feed opening located laterally onsaid outer shaft; (d) said shaft is realized with a double wall, with aninner shaft and an outer shaft; said milling cutter comprises a helicalfluid channel between said inner shaft and said outer shaft; (e) saidinternal channel configured to receive and guide chips comprises adiameter; the diameter of said internal channel configured to receiveand guide chips is at least 75% of said shaft diameter; (f) said shaftis realized with a double wall, with an inner shaft and an outer shaft;the wall thickness of said outer shaft is a maximum of 10% of said shaftdiameter; (g) said shaft is realized with a double wall, with an innershaft and an outer shaft; the wall thickness of said inner shaft is amaximum of 10% of said shaft diameter; (h) said shaft is realized with adouble wall, with an inner shaft and an outer shaft; the wall thicknessof said inner shaft is less than the wall thickness of said outer shaft;and (i) both the rake angle of said face cutting edge and the rake angleof said peripheral cutting edge are greater than 10°.
 40. The methodaccording to claim 39, wherein: said peripheral cutting edge is adjacentto a corner cutting edge on said face cutting edge; said corner cuttingedge, with reference to the direction of the longitudinal axis of saidmilling cutter, is the part of said milling head that is axially thefarthest from said shaft; said peripheral cutting edge encloses an angleof twist of at least 10° with the longitudinal axis of said millingcutter; said milling head has a peripheral step, adjacent to which inthe direction toward said shaft is a tapered area of said milling head;said peripheral cutting edge is adjacent to said peripheral step; saidshaft is realized with a double wall, with an inner shaft and an outershaft; said milling cutter comprises a fluid feed opening locatedlaterally on said outer shaft; said milling cutter comprises a helicalfluid channel between said inner shaft and said outer shaft; saidinternal channel configured to receive and guide chips comprises adiameter; the diameter of said internal channel configured to receiveand guide chips is at least 75% of said shaft diameter; the wallthickness of said outer shaft is a maximum of 10% of said shaftdiameter; the wall thickness of said inner shaft is a maximum of 10% ofsaid shaft diameter; the wall thickness of said inner shaft is less thanthe wall thickness of said outer shaft; and both the rake angle of saidface cutting edge and the rake angle of said peripheral cutting edge areover 10°.